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Another alternative is what I did with my Harris. I was using an early slabside GSXR front end and also found the stem was just a "gnats" too short (could only get the nut on half way) as the top and bottom bearings where the same OD but the top was a smaller ID I used a second bottom bearing in the top and had a "top hat" nut made that screwed through the inner race of the bearing. This meant the bearing was carried on the top hat of the nut not the stem and it picked up on more thread than the original nut would have

The Z1’s had a L shaped bracket at the bottom of the headlight shell to help maintain the horizontal aim. The Kz900 and 1000 lost that bracket and horizontal aim is maintained just by the friction of the rubber dampers and the clamping of the indicator stem nut. 

As for the triple trees, are you sure both upper and lower races are fully seated?

OK, then I guess I just need to make sure I tighten the indicators properly! All the races are properly seated. If they weren't I'd actually have more room between the triples. I'll head over to the garage later and have another look.

Went back and had another look. with everything tightened down i've got about a 3-4mm gap. Looking at the rubber dampers at the bottom of the headlight ears they seem to be quite high - they are 6mm wide and the cap only covers about 3mm. Is this the same with OEM parts?

 


I think I'll put a 2mm spacer at the bottom of the steering stem and then another 1-2mm spacer above the steering stem nut. This will mean that all of the threads on the nut will still be engaging and it will make it easier to adjust the spacer size until everything fits properly. The bolt for the top triple still has a good 15mm of thread engagement.
I checked the steering stops on the lower thriple and they are quite high - the spacer should bring them down pretty much flush with the stop on the steering head.

 

Could you get some of the difference back replacing those giant buffers with “O” rings ?

The rubber “Gasket” as KHI called it, that I have are used and more likely squished some and the measure 5.40mm, with a caliper using a slight friction drag on the “Gasket” in the caliper jaws. So I’d say yours should be good. Something else is goin on. I’m looking for the correct order on the headlight ear stack

I'm pretty sure the headlight ear stack is all OK: rubber gasket, cap/washer for the gasket, chrome covers, headlight ear, cap/washer for the ear. 

I'm pretty sure the bottom bearing is a couple of mm's out. Correcting that would put the steering stops at the correct(?) height. That leaves 1-2mm which is probably due to the headlight ear being 1mm longer (measured it properly today and they are 178mm). Also the cap for the ear doesn't seat properly on the ear - it's just generally a bad fit, I have some OEM ones on the way so maybe they will be better.

Yes, sounds like you have the stack up correct. Make sure the cap that sits over the rubber gasket fits nice into the recess of the trim cover. Sounds like you have a couple items that are each a mm or more out and combined giving you the problem. I do know the rubber gasket does get compressed when installing and tightening the stem bolt. That will push the upper clamp onto the stem and compress the headlight ear stack. See photo of the gasket. The nub at 12 o’clock if formed by the pinch gap of the lower clamp

 

Yeah, I think you're right - everything is out by a fraction and unfortunately all in the same direction so it all adds up. Do you reckon you could take a photo of how the steering stops line up on your A4? Then I can decide whether I should put a spacer under the bottom bearing or just chop the ears.

wrote:

Could you get some of the difference back replacing those giant buffers with “O” rings ?

I think that would just give me even more of a headache when trying to fit the chrome caps. May be worth trying to shave of 1-2mm though.

The tab on the lower clamp is just above the bottom of the frame stop. 

Thanks, looks like I should be fine with a 2 mm spacer.